Intervertebral implant

ABSTRACT

The present invention provides an intervertebral implant for implantation in a treated area of an intervertebral space between vertebral bodies of a spine. The implant includes a spacer portion having an inferior and superior surface, wherein the inferior and superior surfaces each have a contact area capable of engaging with anatomy in the treated area, and the inferior and superior surfaces define a through-hole extending through the spacer body. The present invention further provides holes extending from a side portion to the inferior and superior surfaces of the spacer portion and a plate portion rigidly coupled to the spacer portion, wherein the plate portion contains holes for receiving screws. A fastener back out prevention mechanism adapted on the plate to prevent the back out of the fasteners from the holes and to secure the spacer to the plate of the intervertebral implant.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/574,908 filed on Sep. 18, 2019, which is a continuation of U.S.patent application Ser. No. 15/864,447, filed on Jan. 8, 2018, which isa continuation of U.S. patent application Ser. No. 14/848,827, filed onSep. 9, 2015 (published as U.S. Patent Publication No. 2016/00081815),which is a continuation of U.S. patent application Ser. No. 12/756,438,filed on Apr. 8, 2010 (now issued as U.S. Pat. No. 9,155,631), all ofwhich are incorporated in their entireties herein.

FIELD OF THE INVENTION

The present disclosure generally relates to a fixation device forpositioning and immobilizing at least two adjacent vertebra.

BACKGROUND OF THE INVENTION

The vertebral spine is the axis of the skeleton on which all of the bodyparts “hang”. In humans, the normal spine has seven cervical, twelvethoracic and five lumbar segments. The lumbar spine sits upon thesacrum, which then attaches to the pelvis, and in turn is supported bythe hip and leg bones. The bony vertebral bodies of the spine areseparated by intervertebral discs, which act as joints but allow knowndegrees of flexion, extension, lateral bending, and axial rotation andtranslation.

The typical vertebra has a thick anterior bone mass called the vertebralbody, with a neural (vertebral) arch that arises from the posteriorsurface of the vertebral body. The central of adjacent vertebrae aresupported by intervertebral discs. The spinal disc and/or vertebralbodies may be displaced or damaged due to trauma, disease, degenerativedefects, or wear over an extended period of time. One result of thisdisplacement or damage to a spinal disc or vertebral body may be chronicback pain. In many cases, to alleviate back pain from degenerated ofherniated discs, the disc is removed along with all or part of at leastone neighboring vertebrae and is replaced by an implant that promotesfusion of the remaining bony anatomy. However, the success or failure ofspinal fusion may depend upon several factors. For instance the spaceror implant or cage used to fill the space left by the removed disc andbony anatomy must be sufficiently strong to support the spine under awide range of loading conditions. The spacer should also be configuredso that it likely to remain in place once it has been positioned in thespine by the surgeon. Additionally the material used for the spacershould be biocompatible material and should have a configured thatpromotes bony ingrowth.

In combination with spacers or cages, a plating system is used tofurther stabilize the spine during the fusion process. These devices,commonly referred to as bone fixation plating systems, typically includeone or more plates and screws for aligning and holding vertebrae in afixed position with respect to one another. Plating systems independentof the spacers provide additional complications such as loosening andfailure of the hardware. Two common failures are the breakage of theplates, and the backing out of screws into soft tissues of the patient'sbody. The backing out of the screws is typically a result of the screwsfailure to achieve a sufficient purchase in the bone, although thestripping of the screws has also been known to cause this problem.Another common problems is that plating systems require “carpentry” workto match fit aspects of the vertebral bodies.

There is a need for a spine stabilization system that promotes fusion ofadjacent vertebrae while at the same time provides stabilization of thespinal area where fusion occurs. There is a need for a system thatincorporates both the fusion element and the plating element in onesystem to reduce the possible complications that may occur. There isalso a need to provide a system that reduces the complications that mayoccur in the fusion element and the plating element and a need for thissystem to be configured so that positioning this system is efficient andeasy.

SUMMARY OF THE INVENTION

The present invention provides an intervertebral implant forimplantation in a treated area of an intervertebral space betweenvertebral bodies of a spine. The implant includes a spacer portionhaving an inferior and superior surface, wherein the inferior andsuperior surfaces each have a contact area capable of engaging withanatomy in the treated area, and the inferior and superior surfacesdefine a through-hole extending through the spacer body. The presentinvention further provides screw holes extending from a side portion tothe inferior and superior surfaces of the spacer portion and a plateportion rigidly coupled to the spacer portion through a coupling means,wherein the plate portion contains screws holes for receiving screws. Ascrew back out prevention mechanism is adapted on the plate portion toprevent the back out of screws from the screw holes and to secure theplate portion to the spacer portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of an intervertebralimplant according to the present invention;

FIG. 2 is an exploded view of the embodiment of the implant shown inFIG. 1;

FIG. 3 is a perspective view of the spacer portion of the intervertebralimplant of FIG. 1;

FIG. 4 is a top view of the plate portion of the intervertebral implantof FIG. 1;

FIG. 5 is an exploded view another embodiment of the present invention;and

FIG. 6 is a yet another embodiment of a connection element according tothe present invention.

FIGS. 7A-7B, 8A-8C, and 9A-9B illustrate different embodiments forattaching the spacer portion to a plate portion of an intervertebralimplant.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Embodiments of the disclosure are generally directed to flexiblestabilization systems for use with the anterior, antero-lateral,lateral, and/or posterior portions of at least one motion segment unitof the spine. The systems of the invention are designed to beconformable to the spinal anatomy, so as to be generally less intrusiveto surrounding tissue and vasculature than existing rigid stabilizationsystems.

Certain embodiments may be used on the cervical, thoracic, lumbar,and/or sacral segments of the spine. For example, the size and massincrease of the vertebrae in the spine from the cervical to the lumbarportions is directly related to an increased capacity for supportinglarger loads. This increase in load bearing capacity, however, isparalleled by a decrease in flexibility and an increase insusceptibility to strain. When rigid immobilization systems are used inthe lumbar segment, the flexibility is decreased even further beyond thenatural motion restriction of that segment. Replacing the conventionalrigid immobilization systems with certain embodiments disclosed hereinmay generally restore a more natural movement and provide added supportto the strain-susceptible area.

FIGS. 1-4 illustrate the different views of one particular embodiment ofthe present invention. The intervertebral fusion implant according tothe present invention is a stand-alone interbody fusion device used toprovide structural stability in skeletally mature individuals followingdiscectomies. These implants are available in various heights andgeometric options to fit the anatomically needs of a wide variety ofpatients. As shown in FIG. 1, implant 10 is generally positioned in theintervertebral space between two adjacent vertebrae. Implant 10primarily incorporates a spacer portion 12 and a plate portion 14. Inthis particular embodiment, the spacer portion 12 includes a graftwindow 16 for the placement of bone graft to enhance fusion between twoadjacent vertebrae. The plate portion 14 includes at least one screwhole 18, however, in the preferred embodiment of the present invention,two screw holes 18 are provided. Also, in the plate portion 14 of theimplant 10, pin screw 20 is provided. There is also provided a nut 22which receives the pin screw 20 to secure the spacer portion 12 and theplate portion 14 rigidly to each other. Although a pin screw and a nutare utilized as a blocking mechanism and a plate and spacer attachmentmechanism, any other similar type of arrangement can be also utilized.

It should be noted that the titanium plate portion 14 and the spacerportion 12 maybe coupled through any other feasible means such as hooks,screws, and any other type of fastening means. The implant 10 alsoallows for at least two titanium screws to be inserted at a compoundangle for maximum screw purchase into the superior and inferiorvertebral bodies. The pin screw 20 is provided on the plate portion 14to capture the sides of both of the at least two screws preventing thetitanium screws from backing out. It should be noted that the presentapplication is not limited to being of a PEEK spacer and a titaniumplate. Other materials that are physiologically compatible which aresimilar and which may be unique to spacers and plates may be utilized invarious combinations.

In FIGS. 2 and 3, an exploded view of the intervertebral implant 10 andthe spacer portion 12 are illustrated in greater detail. The implant 10comprises the spacer portion 12, plate portion 14, and a pin screw 20which prevents the back out of the screws as well as securing the plateportion 14 to the spacer portion 12. The spacer portion 12 can becomprised of any material that is conducive to the enhancement of fusionbetween the two adjacent vertebrae. In one particular embodiment, thespacer portion 12 is made of PEEK material which is physiologicallycompatible. It should be noted that any other material that arephysiologically compatible may also be used. The spacer portion 12contains tantalum pins 24 that enable radiographic visualization. Thespacer portion 12 further comprises superior and inferior portions thatare provided with a plurality of pyramidal protrusions 26. The superiorand inferior portions of the spacer portion 12 are bi-convex for greatercontact with the vertebral endplates of the adjacent vertebrae. Theprotrusions 26 can be configured to be any size or shape for furtheranchoring the spacer portion 12 to each of the adjacent vertebrae.Protrusions 26 on the superior and inferior surfaces of each implantgrip the endplates of the adjacent vertebrae to aid in expulsionresistance. Although the protrusions 26 of the preferred embodiment areillustrated as being pyramidal, it should be noted that the protrusions26 may be designed and configured to be any size and shape that furtheranchors the implant to the adjacent portions of the vertebrae. Thespacer portion 12 of the implant also provides a leading edge chamfer 28which enables self distraction of the vertebral bodies while inserting.It should be further noted that although FIGS. 1-4 illustrate a spacerportion that is elongated so that the implant may be positioned duringan lateral access procedure, the spacer portion can be designed andconfigured to be in shape and configuration for accessing the spinethrough any access procedure such as an anterior, posterior and/ortransforaminal.

The spacer portion 12 is designed and configured to receive aninstrument for positioning the implant 10 into the spine. Cutouts 30 areconfigured on the outer opposing sides of the spacer portion 12. Itshould be noted that the length and depth of the cutouts are optimallyconfigured to rigidly hold the implant 10 with the instrument with aminimal amount movement when the holder is attached to the implant.

Now turning to FIGS. 2 and 4, plate portion 14 will be discussed ingreater detail. The plate portion 14 can be comprised of anyphysiologically compatible material. In the preferred embodiment, theplate portion 14 of the implant 10 is composed of titanium. The plateportion 14 is provided with two screw holes 18. However, it should benoted that implant 10 may be comprised of any amount of screw holes 18.The screw holes 18 are situated both in the spacer portion 12 and theplate portion 14 for receiving bone screws which are attached to theadjacent vertebral bodies at different angles. As shown in FIGS. 2, and4, the screw holes 18 are configured to receive screws at differentangles. One screw hole is configured to direct a bone screw into thesuperior vertebrae and the second screw hole is configured to direct asecond bone screw into the inferior vertebrae. The screws enter thescrew holes 18 at specified angles to enter the adjacent vertebralbodies at the optimal locations. The screws are also configured andadapted to provide optimal purchase with the adjacent vertebral bodies.

The plate portion 14 is further provided with a tongue 36 which couplesto a first groove 38 within the cutout of the spacer portion 12. Asillustrated in FIG. 4, tongue 36 is curved to correspond to thecurvature of the first portion of the groove 38 in the spacer portion12. A second groove 40 in the spacer portion 12 is also positioned onopposing sides of the spacer portion 12. The second groove 40 isindependent of the first groove 38. The second groove 40 is designed andconfigured to receive a portion of an instrument. The plate portion 14is also provided with a groove 41 within the tongue 36 which is adaptedto couple to the instrument. As a result, the instrument may be used tosecurely attach the spacer portion 12 and the plate portion 14. Itshould be noted that although the tongue 36 is provided on the plateportion, in alternative embodiments, the spacer portion may contain atongue and the plate portion configured to receive the tongue in agroove.

The plate portion 14 is also provided with knife-protrusions 42positioned on the upper and lower portions of the plate portion 14.These protrusions 42 extend into a portion of the upper and lowervertebrae to help stabilize the implant 10. Specifically, theseprotrusions 42 enable torsional stability of the implant. The plate 14is also provided with “eye brow” like structure which fully captures thebone screws while still allowing for the screws to reside about thetooth root plane and remaining lower than the tooth (protrusions on thespacer portion 12). The plate 14 geometry allows for the minimumreduction of peek volume. The plate 14 height remains level to the peektooth root so that compressive loads are always subjected to the peekbody where the graft is contained. Compound holes are drilled to acceptbone screws and to allow for fixed or variable angle screws. Theanti-back out mechanism is engaged so that the screws do not back out ofthe implant 10.

Turning back to FIG. 2, the preferred embodiment illustrates thecoupling elements 20 and 22 for connecting the plate portion 14 to thespacer portion 12 of the implant 10. Specifically, the pin screw 20 isscrewed into the pin hole and as the pin screw is advanced into thethreaded portion of the nut 22, the spacer portion and the plate portionare securely attached. FIGS. 5 and 6 illustrate different types of nuts44, 46 used receive and secure the pin screw to the spacer portion 12.The nut 46 illustrated in FIG. 6 is round and is provided with amid-line feature to prevent it from backing out. The nut 46 is alsoflanged with flats to prevent rotation.

FIGS. 7A-7B, 8A-8C, and 9A-9B illustrate different embodiments of amechanism to attach the plate portion to the spacer portion. FIG. 7illustrates a plate and spacer comprising a hybrid set screw havingthreaded and serrated portions. The top threaded portion of the blockingset screw is configured to threaded and serrated portions. The topthreaded portion of the blocking set screw may be threaded into theplate while the bottom serrated portion will ratchet into a matingfemale part that is positioned inside the spacer. Once the serratedportion of the set screw is actuated through threaded internal portionof the spacer, a secure single construct is created.

FIGS. 8A-8C illustrates yet another embodiment of a spacer and plateattached via a blocking set screw that is provided with a sloped key atit's distal tip. As the blocking set screw is rotated, the sloped keyacts a cam device and clamps the spacer portion and the plate portiontogether. The blocking set screw may be configured and designed to haveone or more sloped keys depending on the clamping force required tosecurely attach the spacer and the plate portions.

FIG. 9A-9B illustrates yet another mechanism for attaching the spacerportion to the plate portion of an intervertebral implant. In thisparticular embodiment, the spacer portion and the plate portion aresecured via a serrated blocking screw. As the screw is screw isratcheted through the plate and the spacer, the plate and spacer aresecured together. As in the previous embodiments, the spacer portion ofFIGS. 7-9 are provided with features such as superior and inferiorprotrusions, graft hole, and screw holes. Similarly, the plate portionsof FIGS. 7-9 are also provided with screw holes for receiving bonescrews that secure the spacer and plate portions to the vertebrae.

Now, turning to the method of positioning the implant, it should benoted that the intervertebral implant 10 is positioned in the spineafter the disc portion between two vertebral bodies is exposed andremoved using rongeurs and other suitable instruments. The posterior andanterior walls of the annulus are generally preserved to provideperipheral support for the implant and graft materials. A trial deviceattached to a trial holder is then inserted into the disc space todetermine size of the implant. This procedure is generally conductedusing fluoroscopy and tactile feel. After the appropriate sized implantis selected and attached to an implant holder and drill guide, theimplant may be inserted into the disc space. As the surgeon sees fit,the spacer portion of implant may be positioned by itself or the spacerportion and the plate portion may be attached together and thenpositioned within the spine. If the surgeon chooses to position just thespacer portion, then the spacer portion is positioned within the discspace and graft material is used to pack the graft hole for enhancingfusion of the adjacent vertebrae. If the surgeon decides that additionalsupport is required by attaching the plate portion to the spacerportion, the pin screw is used to attach the spacer portion to the plateportion. Once the plate and the spacer are attached, then the implant ispositioned within the disc space. Next, either the combined spacer andplate or just the spacer, the implant is positioned inside the discspace, whereby an awl or any similar type of instrument can be used todrill through the screw hole and break the cortex of the adjacentvertebral body. The surgeon performing this procedure may then use adepth gauge to determine the screw length. Once the appropriate screwlength is determined, screws are inserted using a self-retainingscrewdriver. After the screws are finally inserted and secured therebyproviding solid purchase with the adjacent vertebral bodies, the pinscrew anti-back out mechanism is tightened and secured.

In another embodiment of the present invention, the plate portion is notattached to the spacer portion. The spacer portion is positioned withinthe disc space and bone filler material such bone graft may be delivereddirectly through the screw holes of the spacer portion into the grafthole. Once the bone filler material is inserted and packed within thespacer portion, a separate plate may be used or in the alternative thespacer portion can be used without the additional plate portion or anyother type of plate.

While it is apparent that the invention disclosed herein is wellcalculated to fulfill the objects stated above, it will be appreciatedthat numerous modifications and embodiments may be devised by thoseskilled in the art.

What is claimed is:
 1. An intervertebral implant for implantation in a treated area of an intervertebral space between vertebral bodies of a spine, the implant comprising: a spacer having an inferior surface and a superior surface and screw holes extending from an anterior surface of the spacer to the inferior and superior surfaces, wherein the inferior and superior surfaces each have a contact area capable of engaging with anatomy in the treated area, the spacer having a fastener hole at its anterior surface; a plate coupled to the spacer, the plate having a fastener hole and a plurality of bone screw holes; a fastener positioned through the fastener holes of the plate and the spacer to secure the plate and the spacer together and to simultaneously act as a bone screw blocker to block a bone screw inserted through one of the bone screw holes.
 2. The intervertebral implant of claim 1, wherein the fastener is a screw and the only screw that secures the plate and the spacer together.
 3. The intervertebral implant of claim 1, wherein the fastener is a screw and the only screw that secures the plate and the spacer together, and the only screw that acts as the bone screw blocker.
 4. The intervertebral implant of claim 1, wherein the plate includes a recess on which the fastener is received and wherein a posterior surface of the plate includes first and second extensions configured to mate with first and a second recesses of the spacer.
 5. The intervertebral implant of claim 1, wherein the first and second extensions are curved from a center portion of the posterior surface of the plate to a side surface of the plate and the curved surface corresponds to the curvature of the first and second recesses of the spacer.
 6. The intervertebral implant of claim 1, wherein the plate includes a tongue that mates with a first groove in the spacer.
 7. The intervertebral implant of claim 6, wherein the tongue of the plate has a curvature and is configured to couple to a first groove of the spacer having a corresponding curvature.
 8. The intervertebral implant of claim 1, wherein the fastener includes a pin screw and a nut through which the pin screw is threaded.
 9. The intervertebral implant of claim 8, wherein the pin screw includes a head for blocking the bone screw, an unthreaded shaft extending from the head and a threaded portion extending from the unthreaded shaft.
 10. The intervertebral implant of claim 9, wherein the head is shaped to block and unblock the bone screw based on a circumferential position of the head.
 11. The intervertebral implant of claim 9, wherein the head is shaped to block and unblock two bone screws simultaneously based on a circumferential position of the head.
 12. An intervertebral implant for implantation in a treated area of an intervertebral space between vertebral bodies of a spine, the implant comprising: a spacer having an inferior surface and a superior surface and screw holes, and having a fastener hole at its anterior surface; a plate coupled to the spacer, the plate having a fastener hole and a plurality of bone screw holes; a fastener positioned through the fastener holes of the plate and the spacer to secure the plate and the spacer together and to simultaneously act as a bone screw blocker to block a bone screw inserted through one of the bone screw holes, the fastener having a head shaped to overlie at least one of the screw holes upon rotation of the fastener.
 13. The intervertebral implant of claim 12, wherein the fastener is a screw and the only screw that secures the plate and the spacer together.
 14. The intervertebral implant of claim 12, wherein the fastener is a screw and the only screw that secures the plate and the spacer together, and the only screw that acts as the bone screw blocker.
 15. The intervertebral implant of claim 12, wherein the plate includes a recess on which the fastener is received and wherein a posterior surface of the plate includes first and second extensions configured to mate with first and a second recesses of the spacer.
 16. The intervertebral implant of claim 12, wherein the first and second extensions are curved from a center portion of the posterior surface of the plate to a side surface of the plate and the curved surface corresponds to the curvature of the first and second recesses of the spacer.
 17. The intervertebral implant of claim 12, wherein the plate includes a tongue that mates with a first groove in the spacer.
 18. The intervertebral implant of claim 17, wherein the tongue of the plate has a curvature and is configured to couple to a first groove of the spacer having a corresponding curvature.
 19. The intervertebral implant of claim 12, wherein the fastener includes a pin screw and a nut through which the pin screw is threaded.
 20. The intervertebral implant of claim 19, wherein the pin screw includes an unthreaded shaft extending from the head and a threaded portion extending from the unthreaded shaft. 